Download HEAT PUMP FRUIT DRYER - Worcester Polytechnic Institute

HEAT PUMP
FRUIT DRYER
TECHNICAL MANUAL
Worcester Polytechnic Institute
NTB University, Buchs
Ӧkozentrum
April 30th, 2015
WRITTEN BY: CASEY BROWN, ZACHARY LIPSKY, MARIANA VERTONI, KATHRYN ZIEGLER
To request a copy of this user manual, please contact Stefan Bertsch at [email protected]
TABLE OF CONTENTS
TECHNICAL HANDBOOK OVERVIEW ........................................................................... 1
CHAPTER 1: MACHINE OVERVIEW ............................................................................... 2
FINAL ASSEMBLY ............................................................................................................................... 2
CHAMBERS AND PALLETS ................................................................................................................. 3
ELECTRICAL SYSTEM .......................................................................................................................... 4
HEAT PUMP SYSTEM ......................................................................................................................... 4
CHAPTER 2: SAFETY CONCERNS ................................................................................... 6
CHAPTER 3: INSTALLATION ............................................................................................ 7
CHAMBERS AND PALLETS ................................................................................................................. 7
PARTS LIST..................................................................................................................................... 7
TOOLS LIST .................................................................................................................................... 9
ASSEMBLY INSTRUCTIONS .......................................................................................................... 10
ELECTRICAL SYSTEM ........................................................................................................................ 33
PARTS LIST................................................................................................................................... 33
TOOLS LIST .................................................................................................................................. 38
ASSEMBLY INSTRUCTIONS .......................................................................................................... 40
HEAT PUMP SYSTEM ....................................................................................................................... 54
PARTS LIST................................................................................................................................... 54
TOOLS LIST .................................................................................................................................. 58
ASSEMBLY INSTRUCTIONS .......................................................................................................... 62
CHAPTER 4: OPERATIONS .............................................................................................. 78
TOOLS LIST .................................................................................................................................. 78
PREPARATION INSTRUCTIONS .................................................................................................... 78
FRUIT ANALYSIS .......................................................................................................................... 84
TECHNICAL HANDBOOK OVERVIEW
This handbook was created to guide the user through the construction and operation of the
heat pump fruit dryer. Before any assembly, read the safety concerns in Chapter 2 carefully.
Chapter 1 is an overview of the three sub-assemblies of the fruit dryer (chambers and pallets,
electrical system, and heat pump system). Chapter 3 describes the construction steps for each
of the three sub-assemblies. Chapter 4 outlines the procedures to operate the dryer once
installation is complete. Keep in mind the following important considerations when using this
manual:




The manual was designed assuming that carpenters will build the chambers and
pallets, electricians will assemble the electric system, and air conditioning technicians
will assemble the heat pump system.
The manual was written to provide enough information for the dryer to be assembled
from parts that are ordered and fabricated on-site, without any components or subassemblies shipped.
The dryer can be adapted to suit the resources and materials available in the
community where it is implemented. Aspects of the fruit dryer that can be readily
modified are noted throughout the manual.
The necessary tools to build the dryer can also be adapted to suit the availability of
tools at each location. The recommended tools in the list provided in the handbook
have been labeled with the following priority rank:
High: necessary to complete the fruit dryer.
Medium: perform a task necessary to complete the fruit dryer, but can be
replaced by a tool of similar function.
Low: not necessary, but reduce time to construct the fruit dryer.




The manual includes drying instructions for apples and mangoes. Different fruits and
vegetables can be dried, but make sure to adjust the preparation steps and drying time
accordingly.
The crucial aspect when constructing the drying chamber is to guarantee it is air
tight, waterproof, and food safe (even at high temperatures).
The evaporator, condenser, compressor, and ventilator are unique to the fruit dryer's
heat pump system and must follow exact specifications before any modification
occurs.
The product codes of the electrical components shown in the parts list of the electrical
system pertain to specific manufacturers. These codes will change if similar
components are purchased from different manufacturers.
Heat Pump Fruit Dryer - Technical Handbook
Page 1
CHAPTER 1: MACHINE OVERVIEW
FINAL ASSEMBLY
1
2
4
3
5
Heat Pump Fruit Dryer - Technical Handbook
Page 2
CHAMBERS AND PALLETS
The chambers and pallets make up the structure of the fruit dryer and are comprised of the
heat pump chamber, drying chamber, and pallet assembly.
This section of the manual will be based on the fruit dryer framework built at NTB University
in April 2015 and can be found on page 7. The drying and heat pump chambers in this
manual were made with laminated wood, however this is not necessary as long as the
chambers are waterproof. This can also be accomplished by lining the drying chamber with
foil or replacing the wooden panels with metal. The drying chamber also needs to be air-tight,
with a material that is food safe on the inside. The important areas in which to keep an airtight seal are the corners of the drying chamber shown below. All chamber and pallet
components can be adapted to the resources available.
Heat Pump Fruit Dryer - Technical Handbook
Page 3
ELECTRICAL SYSTEM
The electrical system control’s the compressor, ventilator and the temperature settings for the
heat pump system.
This section of the manual will give an overview based on the materials used in the CUBO
case and can be found on page 33. All electrical components can be adapted to the
resources available.
HEAT PUMP SYSTEM
The heat pump system is what produces the heat to dry the fruits.
Heat Pump Fruit Dryer - Technical Handbook
Page 4
The evaporator, condenser, compressor, and ventilator are specific to this fruit dryer. Exact
specifications are indicated on the parts list that starts on page 54. All other heat pump
components can be adapted to the resources available.
Approximate timeframe for each sub-assembly
Name of section
Number of people required
Heat pump chamber
1
Drying chamber
1
Pallets
2
Electrical system
1
Placing heat pump components
1
Heat pump piping
1
Prepping the heat pump system
1
Operations
2
Heat Pump Fruit Dryer - Technical Handbook
Time required
16 hrs.
16 hrs.
20 hrs.
6 hrs.
2 hrs.
6 hrs.
24 hrs.
20-30 hrs.
Page 5
CHAPTER 2: SAFETY CONCERNS
Caution: can cause minor or moderate injury.
Warning: can cause death or serious injury.
All edges of the wooden panels must be filed or sanded to remove sharp edges and
corners.
When operating heavy machinery (i.e. saws, drills, and grinders), use the utmost
awareness to prevent serious injury.
The ends of the aluminum rail for mounting electrical components must be filed to
remove dangerous sharp edges.
The fins in the evaporator and condenser are extremely sharp and should not be touched
with bare hands.
The water that is produced from the evaporator is deionized and not safe for drinking.
Keep liquids away from all electrical components. Spills can cause electric shocks and
can damage the electrical equipment.
When working with electrical components, always disconnect the power source from any
equipment beforehand to avoid electric shock hazards.
When working with brazing equipment, be aware of high temperatures that can cause
serious burns or lesions.
Be aware that refrigerant leaks are not only harmful for the environment, but can also
cause nausea and headaches.
Cutting tools for preparing the fruit are extremely sharp, so use with caution.
When removing pallets from the fruit dryer, make sure that two people are grasping each
side of the pallet to reduce the risk of injury.
After the heat pump is set up, be aware that the pipes running from the evaporator to the
condenser will be extremely hot.
Heat Pump Fruit Dryer - Technical Handbook
Page 6
CHAPTER 3: INSTALLATION
CHAMBERS AND PALLETS
PARTS LIST
Hardware for Chambers (total)
Dimensions (mm)
5 x 20 Flat Head
5 x 25 Flat Head
5 x 35 Flat Head
5 x 60 Flat Head
5 x 80 Flat Head
6 x 100 Flat Head
8.5/35/2.5
M5
N/A
N/A
Hardware for Pallets
Name
Dimensions (mm)
Screw 06
3 x 16
Screw 07
6 x 120
Mosquito netting
730 x 1345
Wire
11580
String
2940
Heat Pump Chamber
Name
Dimensions (mm)
Panel 01
15 x 970 x 1700
Panel 02
15 x 540 x 970
Panel 03
15 x 445 x 540
Panel 04
15 x 445 x 840
Panel 05
15 x 445 x 840
Panel 06
15 x 220 x 940
Panel 07
15 x 445 x 940
Panel 08
15 x 970 x 1700
Panel 09
15 x 460 x 1110
Panel 10
15 x 540 x 1730
Panel 11
15 x 540 x 970
Panel 12
15 x 460 x 1110
Panel 13
15 x 540 x 1730
Beam 01
100 x 100 x 100
Beam 02
100 x 100 x 500
Beam 03
50 x 50 x 870
Beam 04
50 x 50 x 1700
Beam 05
50 x 50 x 460
Beam 06
50 x 50 x 970
Beams
Wooden Panels
Name
Screw 01
Screw 01
Screw 02
Screw 03
Screw 04
Screw 05
Washer 01
Nut 01
Hinge
Door clamps
Heat Pump Fruit Dryer - Technical Handbook
Number Required
18
27
85
87
35
8
39
39
3
3
Number Required
230
120
10
10
10
Number Required
1
1
2
1
1
1
1
1
1
1
2
1
1
3
4
7
2
6
2
Page 7
Wooden Panels
Beams
Beams
Name
Panel 14
Panel 15
Panel 16
Panel 17
Panel 18
Panel 19
Panel 20
Beam 03
Beam 07
Beam 08
Beam 09
Beam 10
Beam 11
Beam 12
Beam 13
Name
Beam 14
Beam 15
Beam 16
Drying Chamber
Dimensions (mm)
15 x 970 x 1900
15 x 1235 x 1900
15 x 840 x 1235
15 x 970 x 1900
15 x 840 x 1592
15 x 970 x 1315
15 x 375 x 1315
50 x 50 x 870
50 x 50 x 1900
50 x 50 x 1200
50 x 50 x 870
50 x 50 x 1117
50 x 50 x 1135
35 x 42 x 1592
50 x 60 x 840
Pallets
Dimensions (mm)
35 x 40 x 1435
50 x 50 x 1535
50 x 60 x 730
Number Required
1
2
1
1
1
2
2
7
4
8
2
2
2
2
1
Number Required
2
2
3
This drying and heat pump chambers were built with laminated wooden panels of 1.5 cm thickness.
Other thicknesses can be used, but the dimensions shown in the table need to be adjusted accordingly.
The chambers can also be made of metal or lined with foil.
The choice of the material needs to ensure that the drying chamber is air-tight, waterproof,
and food safe.
Heat Pump Fruit Dryer - Technical Handbook
Page 8
TOOLS LIST
Necessary Tools
Abrasive Material
Measurement Tool
Used to shape or polish a work piece
Saw
Drill
Heat Pump Fruit Dryer - Technical Handbook
Clamp
Used to hold objects tightly
together)
Assorted Drill Bits
Page 9
Countersink Drill Bit
Used to widen the entrance of a hole to allow
for the screw head to sit flush with the
surrounding material.
ASSEMBLY INSTRUCTIONS
SECTION 1: Prepare the wooden panels and beams
Step #1: Cut the wooden panels and beams
Cut the wooden panels and beams, following the example above:
1. Use the drawings that follow to mark the cuts on the wooden panels and beams.
2. Cut the wooden panels and beams according to the specified dimensions (all in mm).
Heat Pump Fruit Dryer - Technical Handbook
Page 10
Panel 02
Panel 03
Panel 04
Panel 05
Heat Pump Fruit Dryer - Technical Handbook
Page 11
Panel 06
Panel 08
Panel 14
The 210 mm dimension for one of the openings in Panel 08 and Panel 14 is designed to match
the dimensions of the ventilator that is chosen for the dryer (see section on the heat pump
system). If a different ventilator is selected, this dimension must be adjusted to suit the
dimensions of the ventilator.
Heat Pump Fruit Dryer - Technical Handbook
Page 12
Panel 12
Panel 13
Panel 15
Heat Pump Fruit Dryer - Technical Handbook
Page 13
Panel 16
Panel 17
Beam 09
Heat Pump Fruit Dryer - Technical Handbook
Page 14
Panel 18
Step #2: Sand
1. File the wooden panels.
2. File the beams.
Heat Pump Fruit Dryer - Technical Handbook
Page 15
SECTION 2: Assemble the heat pump chamber
Example Step
All steps described in Sections 2 and 3 are formated as shown:


The image on the left depicts the piece (in blue) that is being added to the system.
The image on the right shows the placement of all screws in that piece. Note that
since dimensions are not specified, an approximate placement is sufficient.
Step #1
Place and fasten four Beam 02’s under Panel 01 (interior side of the panel facing up).
Always countersink the
holes so that the tops of
the screw heads will be
flush with the surface.
The reference “Interior Side” indicates the
side of the wood that is water resistant and
food safe. If the inside of the drying chamber
will be lined with other materials that fit the
requirements, disregard orientation.
Heat Pump Fruit Dryer - Technical Handbook
Page 16
Step #2
Place and fasten the three Beam 01’s under the center of the wooden panel.
Step #3
1. Lay and fasten two Beam 04’s lengthwise so that they are flush with the sides of Panel
01.
2. Lay five Beam 03’s across Panel 01 between the Beam 04’s.
Step #4
Place and fasten Panel 02 (interior side facing up) on top of the beams, flush with the end
of the dryer.
Heat Pump Fruit Dryer - Technical Handbook
Page 17
Step #5
Place and fasten four Beam 05’s upwards in each of the corners of Panel 02.
Step #6
Fasten two Beam 03’s to be flush with the end of the dryer: one on top of Panel 02 and
another flush with the tops of Beam 05’s.
Step #7
Place two Panel 03’s so that the interior sides are facing each other.
Heat Pump Fruit Dryer - Technical Handbook
Page 18
Step #8
Slide one Beam 06 through the bottom cutouts of both Panel 03’s so that it is flush with the
long sides of Panel 01.
Step #9
Place the other Beam 06 in the top cutouts of both Panel 03’s.
Step #10
Install ventilation and attach Panel 04 and Panel 05 with the interior sides facing each
other. Place Panel 04 in between the two Beam 06’s.
Heat Pump Fruit Dryer - Technical Handbook
Page 19
For details on instalation of the ventilation, see ‘Assembly Instructions’ in
the ‘Heat Pump System’ section.
Step #11
Place and fasten two Beam 05’s oriented vertically in each of the remaining corners of
Panel 01.
Step #12
Place and fasten Panel 06 (interior side up) flush with the end of the dryer that is opposite
of Panel 05.
Step #13
Attach Panel 07 (interior side facing inwards) against the insides of the Beam 05’s on top
of Panel 06. Make sure that the sides of the plate are 15 mm from the edges of the beams.
Heat Pump Fruit Dryer - Technical Handbook
Page 20
Step #14
Place Panel 08 (interior side facing down) on top of the assembly.
STOP
Leave one side of the heat pump
chamber open until the heat pump is
inserted into the chamber and has
been tested to run properly.
Heat Pump Fruit Dryer - Technical Handbook
Page 21
Step #15
Place and fasten Panel 09 (interior side facing inwards) to fit on the right side of the
chamber, and fasten Panel 12 similarly on the left side of the chamber.
Step #16
Place and fasten Panel 10 (interior side facing out) to the exterior of Panel 09 and Panel 13
to the exterior of Panel 12.
Step #17
Place and fasten two Panel 11’s (interior side facing out) to the short ends.
Heat Pump Fruit Dryer - Technical Handbook
Page 22
SECTION 3: Assemble the drying chamber
Step #1:
Place Panel 14 interior side facing up.
Step #2
Place and fasten two Beam 07’s flush with the long sides of Panel 14.
Step #3
Place and fasten eight Beam 08’s oriented vertically to the two Beam 07’s. These are
drilled from the BOTTOM of Panel 14.
Heat Pump Fruit Dryer - Technical Handbook
Page 23
Step #4
Place and fasten three Beam 03’s on Panel 14: two flush with either end of the drying
chamber and one aligned with two Beam 08’s.
Step #5
Place and fasten the two Beam 09’s that were cut to the interior side of Panel 14, with the
cut sides facing up and one end flush with the edge of the 210 x 840 cutout.
Step #6
Place and fasten two Beam 10’s flush with the corners of the 210x840 cutout of Panel 14
Heat Pump Fruit Dryer - Technical Handbook
Page 24
Step #7
Place and fasten Beam 03 between the two Beam 08’s 15 mm from the top of the beams.
Step #8
Place and fasten the two Panel 15’s (interior sides facing each other) oriented vertically on
the interior sides of the Beam 08’s.
Step #9
Place and fasten Panel 16 (interior side facing inwards) oriented vertically against the two
Beam 03’s.
Heat Pump Fruit Dryer - Technical Handbook
Page 25
Step #10
Place the Panel 17 (interior side facing down) on the top of the dryer.
Step #11
Place and fasten two Beam 07’s on the top of the dryer, flush with the long sides.
Step #12
Place and fasten three Beam 03’s on the top of the dryer.
Heat Pump Fruit Dryer - Technical Handbook
Page 26
Step #13
Place and fasten Panel 18 (interior side facing up) on top of the Beam 09’s and Beam 10’s
so that it is flush with the back of the dryer. Make sure that the holes are not blocked by the
beams.
Step #14
Place and fasten two Beam 11’s against Panel 16 so that they are between both Beam 03’s.
Step #15
Place and fasten Panel 19 to the Beam 03s and Beam 08’s.
Heat Pump Fruit Dryer - Technical Handbook
Page 27
Step #16
Place and fasten Beam 12’s to the interior side of Panel 18, flush with either end.
Step #17
Both sides
Place and fasten Beam 13 so that it is on the interior side of the Panel 15’s.
Step #18
Place and fasten two Panel 19’s to the Beam 08’s so they are flush with the top and bottom
of the Beam 07’s.
Heat Pump Fruit Dryer - Technical Handbook
Page 28
Step #19
Attach a Panel 19 to either side of Panel 21’s using a hinge on one side and a latching
mechanism on the other side to allow the door to open and close.
SECTION 4: Assemble the pallets
Step #1:
Place two Beam 14’s 760 mm apart.
Step #2:
Place and fasten two Beam 15’s to the two Beam 14’s so that the beams are flush with one
another.
Heat Pump Fruit Dryer - Technical Handbook
Page 29
Step #3:
Place and fasten three Beam 16’s in between the two Beam 15’s.
Step #4:
Drill 6 screws into the Beam 16’s on the outer edges of the pallet that are 10 cm apart.
Leave enough room beneath the screw head to wrap wire around the screw.
Step # 5:
Wrap wire around the screws and tie off both ends.
Heat Pump Fruit Dryer - Technical Handbook
Page 30
Step #6:
Tighten the wire by placing additional screws in the locations shown to take up slack.
Tighten all screws.
Step #7:
Staple the ends of the netting on one corner of the pallet.
Step #8:
Run string along the inner edge of the pallet and fold the edge of the netting around the
string, then staple the netting and string to the pallet.
Heat Pump Fruit Dryer - Technical Handbook
Page 31
Step #9:
Cut the end of the string and add staples when necessary to attach loose portions of netting.
Step #10:
Repeat steps 1-9 to make more pallets.
Heat Pump Fruit Dryer - Technical Handbook
Page 32
ELECTRICAL SYSTEM
One-phase System
Three-phase System
The power components shown in this section are based on a three-phase system. A one-phase
system can be adapted with the addition of a capacitor. Schematics for both phases are
provided at the end of the section.
PARTS LIST
Name
Screw 06
Screw 07
Screw 08
Screw 09
Wire 01
Wire 02
Hardware for Electrical components
Dimensions (mm)
Number Required
3 x 20
16
3.5 x 20
4
5 x 45
12
5 x 60
3
1.5
4.5 meters
0.75
12 meters
Electrical Components
Electrical Case
(CUBO O 300x400x180)
Dimensions (cm): 30 x 40 x 18
Number required: 1
Heat Pump Fruit Dryer - Technical Handbook
Mounting plate
(Lochplatte 270x370)
Dimensions (cm): 27 x 37
Number required: 1
Page 33
Wall mounting brackets
(Wandbef.lasche zu CUBO)
Lock nut M20
(Gegenmutter Polyamid M20Agro)
Number required: 7
Number required: 1
Cable gland M20
(Polyam.-Verschraub.M20 Agro)
Power cord
(Cable 3*2.5mm2)
Number required: 7
Circuit breaker for the compressor*
(LS-Schalter Hager C 6KA 3P 10A)
Number of wires: 3
Contactor
(DIL EM 10 (230VAC))
Number required: 1
Heat Pump Fruit Dryer - Technical Handbook
Number required: 1
Page 34
Feed-through terminal block**
(R-Klemme 4mm2)
Ground terminal
(Trennwand)
Number required: 14 grey, 3 blue
Number required: 6
Ground partition
(Erdklemme 4 mm2, blank)
Locking piece
(Arretierstuck)
Number required: 6
Number required: 6
Circuit breaker for the ventilator
(LS C6A 1pol)
Multifunction time relays
(CS2/UC12-240V)
Number required: 6
Number required: 1
Heat Pump Fruit Dryer - Technical Handbook
Page 35
Switch for the ventilator
Switch for the 2 temperature modes
(P220-61062-003M1-S)
(P220-61025-003M1)
Number required: 1
Number required: 1
Transformer
Potentiometer
(RLTS80)
(SP-01/1M)
Number required: 1
Number required: 1
Emergency Cutoff
(PS2-W7A)
Adapter rail for terminalys and
relays (Hutschiene 35mm)
Number required: 1
Heat Pump Fruit Dryer - Technical Handbook
Dimensions (cm): 3.2 x 0.37
Number required: 2
Page 36
Capacitor for the fan (GC 6uF)
Analog temperature meaurement
Number required: 1
Number required: 1
Temperature switches
(heatTHERM-AT)
Number required: 2
* Picture shown is for a three-phase system, but one-phase can be used as
well (LS C13A 1pol)
** Can be replaced with simple soldering
Heat Pump Fruit Dryer - Technical Handbook
Page 37
TOOLS LIST
Necessary Tools
Assorted Screwdrivers
Needle-Nose Pliers
Wire Cutters
Wire Strippers
Crimping Tool
Zip-Ties
Used to fasten crimps to wires
Heat Pump Fruit Dryer - Technical Handbook
Page 38
Drill
Assorted Large Diameter Drill Bits
Used to cut holes in the plastic
electrical case
Deburring Tool
Used to remove sharp edges from metals
or plastics
Heat Pump Fruit Dryer - Technical Handbook
Page 39
ASSEMBLY INSTRUCTIONS
SECTION 1: Assemble the plastic case for electronics
Step #1:
Attach the case extension using the four black threaded pegs.
Step #2:
Tighten the threaded pegs using the grey screwdriver fitting provided.
Heat Pump Fruit Dryer - Technical Handbook
Page 40
Step #3: Drill
Mark and drill 6 evenly spaced 20 mm diameter holes for cable fittings that are
approximately 4 cm from the bottom of the case.
There are two templates attached on the following pages that can be used
as a guide for the drilling in steps #3 and #4.
Step #4: Drill
Mark and drill 4 holes 5 mm in diameter for each switch plate.
Step #5: Drill
Mark and drill a 20.5 mm hole for the potentiometer.
Heat Pump Fruit Dryer - Technical Handbook
Page 41
Heat Pump Fruit Dryer - Technical Handbook
Page 42
Heat Pump Fruit Dryer - Technical Handbook
Page 43
SECTION 2: Assemble the components within the electrical case
Step #1: Remove sharp edges
File the ends of the aluminum rail for placing electrical components.
Step #2: Drill
Tap three M4 thread size holes in the metal screen for mounting the aluminum rail.
Step #3: Screw
Drill three holes (diameter 4.5 mm) in the aluminum rail and mount the rail on the metal
screen with screws that correspond to the size of the tapped holes.
Heat Pump Fruit Dryer - Technical Handbook
Page 44
Step #4: Place Terminals
Follow electrical schematics on the following pages, and attach the terminals to the
aluminum rail. Begin by attaching the transparent terminal that acts as a stopper to the left
end of the aluminum rail.
Step #5: Label
Label the terminals as shown in the appropriate schematics.
Step #6: Wire
Cut wires to connect the components as shown in the schematics. Strip the wire ends, place
end fittings, and crimp the wires before inserting them into the cages.
If the wire insulation is pinched in the cages, a full contact might not be
made with the wire.
Heat Pump Fruit Dryer - Technical Handbook
Page 45
Schematic for a one-phase system: Compressor
Heat Pump Fruit Dryer - Technical Handbook
Page 46
Schematic for a one-phase system: Ventilator
Heat Pump Fruit Dryer - Technical Handbook
Page 47
Schematic for a one-phase system: Controller
Heat Pump Fruit Dryer - Technical Handbook
Page 48
Schematic for a three-phase system: Controller
The schematics for the compressor and ventilator for a three-phase system
are the same as the ones for a one-phase system.
1F3
3K4
1 3 5
2 4 6
M
3~
Heat Pump Fruit Dryer - Technical Handbook
Page 49
Completed circuit for a one-phase system
Completed circuit for a three-phase system
Heat Pump Fruit Dryer - Technical Handbook
Page 50
SECTION 3: Attach the electrical components to the dryer
Step #1:
Attach the electrical case, analog temperature gauge, and two temperature switches to the
front Panel 11 of the dryer.
STOP
Move on to the heat pump system
assembly before continuing this
section in order to wire electrical
components to the heat pump.
Heat Pump Fruit Dryer - Technical Handbook
Page 51
Step #2:
Attach the wiring to their proper locations:
Fan
Compressor
Emergency cutoff (heat pump)
Temperature switch for mode 1
Temperature switch for mode 2
:
Power cord
:
Step #3:
When inserting the copper wire from the temperature switch make sure that it goes through
the fan chamber, into the center to the ventilator.
Heat Pump Fruit Dryer - Technical Handbook
Page 52
Step #4:
Wire the inside of the temperature switches.
Step #5:
Set the maximum and minimum range of the temperature controls:
Temperature switch for mode 1: 35-73 ºC
Temperature switch for mode 2: 25-45 ºC
Heat Pump Fruit Dryer - Technical Handbook
Page 53
HEAT PUMP SYSTEM
PARTS LIST
Name
Hardware for Heat pump assembly (total)
Dimensions (mm)
Screw 10
Screw 11
Screw 12
Screw 13
Screw 14
Screw 15
Screw 12
Washer 02
Washer 03
Washer 01
Washer 04
Nut 02
Rivet
Elbow Joints
Tubing
Threaded Slotted Insert
Wooden
Panels
Piping
Name
Panel 21
M4 x 10 Machine Screw
M4 x 35 Machine Screw
4.5 x 20 Pan Head
4.5 x 45 Pan Head
5 x 20 Pan Head
M6 x 20 Machine Screw
M8 x 40 Machine Screw
4.3/12/1
5.3/15/1.2
5.4/15/1.2
8.5/35/2.5
M4
2.4 or 3.0
½ Zoll – ¾ Zoll
Diameter: 3.5
Length: 2000
Inside diameter: M8
Outside diameter: M12
Length: 18
Diameter: 6.4
Diameter: 8
Diameter: 12.6
Diameter: 19
Parts
Dimensions (mm)
24 x 940 x 940
Heat Pump Fruit Dryer - Technical Handbook
Number Required
30
4
20
4
6
4
4
54
12
16
4
34
8
5
Length: 2000 mm
4
Length: 39.7 mm
Length: 10 mm
Length: 100 mm
Length: 112 mm
Number Required
2
Page 54
The compressor, condenser, evaporator, and ventilator must be ordered as
specified.
Heat Pump Components
Compressor
Number required: 1
3
Flow Rate: 6.8 𝑚 ⁄ℎ
Must be able to sustain:
Evaporator temperature: 25ᵒC
Condenser temperature: 65ᵒC
Condenser
Number required: 1
Total surface area: 10 𝑚2
Fin Spacing > 3.5 𝑚
Overall heat rate trasnfer: 8 kW
Dimensions: 920 x 410 x 160 mm
Evaporator
Ventilator
Number required: 1
Total surface area: 10 𝑚2
Fin Spacing > 3.5 𝑚
Overall heat rate trasnfer: 6 kW
Dimensions: 920 x 410 x 90 mm
Number required: 1
3
Flow Rate: 1500 𝑚 ⁄ℎ
Pressure: 80 Pa
Temperature: 70ᵒC
Variable Speed
Dimensions: Thickness 216mm
Outside Diameter 330mm
Heat Pump Fruit Dryer - Technical Handbook
Page 55
Metal Shroud
Number required: 1
Dimensions: match ventilator
Sight Glass
Number required: 1
Pressure Valve
Dimensions: ¾”
Number required: 1
Schrader Valve Core
Number required: 2
Heat Pump Fruit Dryer - Technical Handbook
Refrigerant Filter Drier
Number required: 1
Metal Bracket
Number required: 2 or 4
Pressure Valve
Dimensions: ½”
Number required: 1
T Joint
Number required: 2
Page 56
Insulation
Emergency Cutoff
Length required: 1 meter
Number required: 1
Metal Strap
Valve Seal
Number required: 1
Expansion Value with Thermometer
Number required: 1
Heat Pump Fruit Dryer - Technical Handbook
Number required: 4
Wire
Length required: 1.5 meter
Page 57
TOOLS LIST
Necessary Tools
Abrasive Material
Measurement Tool
Used to shape or polish a work piece
Metal Saw
Drill
Heat Pump Fruit Dryer - Technical Handbook
Metal Cutter
Brazing Equipment
Page 58
Countersink Drill Bit (High)
Assorted Drill Bits
Used to drill out the end of an open pipe to
allow the solder to better fill the pipe
joint.
Pipe Cutter
Pipe Bender
Cleaning Material
Deburring Tool
Pipe Expander
Compressed Air Hose
Heat Pump Fruit Dryer - Technical Handbook
Page 59
Hammer
Pressure Monitor
Grinder
Solder & Flux
Vacuum Pump
Riviter
Bench Vice
Allen Wrench
Heat Pump Fruit Dryer - Technical Handbook
Page 60
Insulation Tape
Insulation Glue
Electrical Tape
Wrench
Assorted Screwdrivers
Heat Pump Fruit Dryer - Technical Handbook
Page 61
ASSEMBLY INSTRUCTIONS
It is highly important to clean all piping component through the process of
building the heat pump system. Foreign contaminants could restrict or damage
the operation of the system.
SECTION 1: Install ventilation
Step #1
Center and fasten the metal shroud on Panel 04 (interior side up).
Step #2
Overhead view
Place and fasten the ventilator in place by securing it to Panel 05 and the Metal Shroud.
Adjust the ventilator accordingly to prevent rubbing from occuring between
the ventilator fan and the shroud when the fan is spinning.
Heat Pump Fruit Dryer - Technical Handbook
Page 62
SECTION 2: Construct water collector
Step #1
Obtain a metal sheet measuring 190 x 1000 mm in area. Cut the corners of the sheet to
create foldable sides that are 30 mm tall.
Step #2
Fold the sides up and create four 90 degree corners.
Step #3
Rivet each side of the corners with 2.4 or 3.0 mm rivets.
Heat Pump Fruit Dryer - Technical Handbook
Page 63
Step #4
Make two cuts near the center of one end of the water collector to create a spout for the
water to exit through.
Step #5
Place the water collector on Panel 21 so that the back corner is flush with the back corner
of the panel.
Heat Pump Fruit Dryer - Technical Handbook
Page 64
SECTION 3: Fasten condenser, compressor, and evaporator
Step #1
Attach four 90 degree metal brackets to the flanges on the condenser that are facing the
evaporator.
Be careful to not puncture any of the metal tubing while drilling.
For safety, file the holes after drilling to remove sharp edges.
Step #2
Insert rubber bushings into the mounting points for the compressor.
Heat Pump Fruit Dryer - Technical Handbook
Page 65
Step #3
Place and fasten the compressor using the threaded slotted inserts, and the Washer 04’s.
This washer size is crucial to hold the compressor securely in place if the
fruit dryer is transported.
Step #4
Place and fasten the condenser on Panel 21 (interior side facing up) with the back edge of
the condenser flush with the edges of the panel.
Heat Pump Fruit Dryer - Technical Handbook
Page 66
Step #5
Place the evaporator in the water collector so that its back corner is also aligned with the
back corner of the collector plate.
Step #6
Drill a hole in the rear flange of the evaporator to allow for the rivet.
Step #7
Cut two triangular pieces of wood and make the required cuts as shown. These will act as
brackets to hold the evaporator and water collector in place.
Heat Pump Fruit Dryer - Technical Handbook
Page 67
Step #8
Fasten the wooden brackets in place.
Heat Pump Fruit Dryer - Technical Handbook
Page 68
SECTION 4: Assemble the piping
Side View
Each number represents a connecting location in the heat pump system.
Step #1
Top View
Side View
Connect location 1 to location 2 using piping, a reducer, and a T joint.
Allow for enough additional piping to dampen vibrations and reduce the risk of
failure.
Heat Pump Fruit Dryer - Technical Handbook
Page 69
Step #2
Top View
Side View
Connect location 3 to location 4 using piping, a reducer, a T joint, and the expansion valve
(with thermometer).
Step #3
Top View
Side View
Connect location 5 to location 6 using piping, a reducer, the refrigerant filter drier, and the
sight glass.
This filter dryer must be oriented to match the refrigerant flow direction. A label on
the filter indicates the proper flow direction.
Heat Pump Fruit Dryer - Technical Handbook
Page 70
Step #4
Side View
Front View
Fasten the thermometer reservoir from the expansion valve to the piping from location 5 to
location 6. The reservoir must be oriented at a 1 o’clock position around the pipe if the pipe
diameter is ½ Zoll, and at a 3 o’clock position if the pipe diameter is ¾ Zoll.
SECTION 5: Install emergency cutoff
Step #1
Top View
Side View
Place and fasten the emergency cutoff switch.
Heat Pump Fruit Dryer - Technical Handbook
Page 71
Step #2
Top View
Side View
Connect location 7 to location 2 and location 8 to location 3 using flexible tubing.
Step #3
Set the pressure minimum to 1.5-2.0 bar and the pressure maximum to 20-25 bar.
Heat Pump Fruit Dryer - Technical Handbook
Page 72
SECTION 6: Perform pressure test
Step #1
Attach a vacuum pump to the high and low pressure fittings on the compressor and run the
vacuum pump overnight to remove moisture from the heat pump system.
Step #2
Check the sight glass after the vacuum test is completed to make sure that the system is
DRY.
Heat Pump Fruit Dryer - Technical Handbook
Page 73
Step #3
Use pressurized nitrogen to pressurize the system to 10 bar.
Step #4
Wait 5 hours, and make sure that the pressure remains at 10 bar. If there is no leak, then the
pressure can be released.
Heat Pump Fruit Dryer - Technical Handbook
Page 74
SECTION 7: Attach insulation
Step #1
Insulate the piping connection from location 3 to location 4.
Insulation will decrease the refrigerant’s heat loss when moving from the evaporator
to the compressor, increasing the efficiency of the heat pump.
SECTION 8: Attach the lid
Step #1
Place the second Panel 21 on top of the heat pump assembly and fasten it to the 90 degree
metal brackets on the condenser and evaporator.
Heat Pump Fruit Dryer - Technical Handbook
Page 75
SECTION 9: Add refrigerant
Step #1
Re-attach the vacuum pump and create a vacuum in the system to remove moisture.
Step #2
Turn on the ventilator and begin adding refrigerant to the low pressure fitting on the
compressor.
Instructions for turning on the ventilator and compressor can be found in
Operations Section 3.
Step #3
When the amount of refrigerant added reaches 1000-1500 grams, turn on the compressor.
Step #4
Gradually add refrigerant until the amount of refrigerant added reaches 2200 grams.
Heat Pump Fruit Dryer - Technical Handbook
Page 76
Step #5
Disconnect the refrigerant hoses and check the sight glass to make sure that the color
depicts DRY and that there are no bubbles visible.
Step #6
Adjust the regulator in the expansion valve as necessary to prevent overheating of the
system.
Heat Pump Fruit Dryer - Technical Handbook
Page 77
CHAPTER 4: OPERATIONS
The manual includes drying instructions for apples and mangoes. Different fruits and
vegetables can be dried, but make sure to adjust the preparation steps and drying time
accordingly.
TOOLS LIST
Tools for Preparing the Fruits
Knife
Peeler
PREPARATION INSTRUCTIONS
SECTION 1: Prepare the apples
Step #1
Wash the apples and wipe off the excess water.
Heat Pump Fruit Dryer - Technical Handbook
Page 78
Step #2
Decore the apples.
Step #3
If desired, peel the apples. This is not required and depends on the consumer’s preference.
Step #4
Cut slices of approximately 5 mm.
If the apples will not be imediately dried after the preparation, place the slices into a
container with water and lemon juice to keep the apples from getting brown.
Heat Pump Fruit Dryer - Technical Handbook
Page 79
SECTION 2: Prepare the mangoes
Step #1
Wash the mangoes.
Step #2
Peel the mangoes.
Step #3
Cut slices of approximately 7 mm, avoiding the pit.
Heat Pump Fruit Dryer - Technical Handbook
Page 80
SECTION 3: Turn on the dryer and load fruits
Step #1: Turn on the fruit dryer
Step #2
Place a container for water underneath the spout of the water collector.
CAUTION: DO NOT DRINK THE WATER! It is only for general cleaning (e.g. the dryer).
Heat Pump Fruit Dryer - Technical Handbook
Page 81
Step #3
Place the fruit slices onto the pallets so they are not overlapping. Completely cover the area
of the netting, but DO NOT place fruits over the wooden sections.
Dry the mangoes imediately after preparing them.
them.
Step #4
Insert the pallets into the drying chamber. Avoid leaving the door open whenever possible
Heat Pump Fruit Dryer - Technical Handbook
Page 82
SECTION 4: Unload fruits and turn off the dryer
Step #1: Unload fruits
When the fruits on the bottom pallet have finished drying (see below), remove the pallet
and unload the dried fruits. A new pallet of fruits can then be inserted on top of the stack if
a continuous operation is desired.
Step #2: Turn off the dryer
When the entire operation is finished, turn off the dryer:
1. Turn off the compressor to position 0.
2. Increase the ventilator to position 3, and let the dryer air out for 10-15 minutes.
4. Turn off the ventilator to position 0.
Examples of the final products
The drying time depends on:





Fruit or vegetable being dried.
Thickness of the slices (thicker slices dry more slowly).
Size of the slices (bigger slices dry more slowly).
Location in the drying chamber in which the fruits are dried (top pallets dry more
slowly).
Total amount of fruits loaded to the dryer.
Because of all these variations, a precise time cannot be provided. The examples on the next
page can be used as guidance. Ultimately, the decision will depend on consumer’s preference.
Heat Pump Fruit Dryer - Technical Handbook
Page 83
FRUIT ANALYSIS
APPLES
Fresh apples on one pallet: 3.75 kg
Approximate desired weight of dried apples from one pallet: 400 g – 500 g
Approximate drying time: 10 hours – 14 hours
Too crispy!
Too moist!
Time: 16 hours
Time: 4 hours 30 min
Weight per pallet: 380 g
Weight per pallet: 800 g
MANGOES
Approximate weight of fresh mangoes to load one pallet: 7.30 kg
Approximate desired weight of dried mangoes from one pallet: 600 g – 800 g
Approximate drying time: 14 hours – 20 hours
Finished
Heat Pump Fruit Dryer - Technical Handbook
Unfinished
Page 84